Accurate and consistent processing
All palletizing systems, whether traditional or automated, require the use of pallets as a loading platform for picking and placing goods. The two most common types of pallets used are wooden pallets or plastic pallets.
Wooden pallets can cause several problems for the palletizing system. Since traditional palletizing relies on manual labor to perform tasks, operators using wooden pallets are at greater risk of injury due to loose nails and debris. These can also block and stop automatic palletizers, causing costly damage and interruption of operations.
Plastic pallets are increasingly becoming the pallet of choice for palletizing systems because they are integrally injection molded to provide 100% consistency in size and strength. When used in a robotic palletizing system-as shown in the video using our IPS Hygienic 1210 5R plastic pallet-this allows accurate positioning of the pallet and more accurate loading of goods on the pallet deck.
Although the video shows that a plastic pallet is being loaded, this is only the beginning of the journey. An empty plastic pallet is first sent to the robot palletizer, and then the box is moved into the palletizing unit. In RARUK's Robotiq palletizing solution, reflective sensors detect the boxes picked up by the robot and start stacking them on pallets. Once filled, the plastic pallet is likely to be sent to an automatic conveyor belt, where it passes through the system and is ready to be sent. For such automated applications, our durable plastic pool trays (such as our APB 1210 Pool Tray 5R) provide the ideal solution. This plastic pallet has a dynamic load capacity of 2500 kg and a shelf capacity of 1250 kg. It is very sturdy and can work seamlessly in an automated system with minimal deflection under load.
Manufacturing flexibility
Traditional palletizing systems—often referred to as hard automation—traditionally can only handle one type of product, which makes them inflexible and it is often impossible for manufacturers to adapt to other types of products. Modern manufacturing has increasingly higher requirements for flexibility, and traditional palletizing systems simply cannot meet these requirements.
The design of the robot palletizer fully considers flexibility. Installation, setup and configuration are quick and easy, and they can handle frequent changes in tasks and different box and pallet sizes. For example, the UR10e robot in the video can pick up various boxes and handle payloads up to 16 kg. It can also cover a wide range of heights and different pallet sizes with a small footprint, which means it can easily adapt to existing floor plans.
Eliminate the risk of injury
Based on the 693,000 non-fatal workplace injuries reported in the 2019/20 Workforce Survey, the Health and Safety Executive (HSE) stated that 19% were caused by moving, lifting or moving.
Integrating the robotic palletizing system into the manufacturing operation eliminates the need for workers to perform any repetitive or burdensome tasks such as bending, lifting and twisting, thereby eliminating the risk of operator injury.
Higher throughput
The rapid growth of e-commerce has put continuous pressure on manufacturers, requiring them to increase productivity and delivery speed at an unprecedented rate; for many retailers who once admired next-day delivery services, same-day delivery services are now on the rise.
It is not feasible for any worker to promise a 24-hour shift, but in contrast, robotic palletizers are designed for endurance. Compared with any other palletizing method, the robotic palletizing system can handle more boxes in a shorter time, thereby increasing throughput. For example, the Robotiq palletizing solution can be loaded at a rate of up to 13 boxes per minute—if you increase the number of palletizing robots used, it can significantly increase throughput.
Cost savings and return on investment
Although there are initial costs when using robotic palletizing systems, because they provide a completely flexible automation solution-in terms of the different pallet sizes and product types they can adapt to-they provide more cost than traditional systems Effective alternatives.
Another cost advantage of using robotic palletizers with plastic pallets is that manufacturers can quickly obtain a return on investment by increasing productivity and throughput. These robotic systems are durable-just like our plastic pallets, they have an expected lifespan of up to 10 years, usually more than 10 years.
